Installation (from 07/2011)
HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT (for Hatchback): INSTALLATION
1. INSTALL NO. 2 AIR DUCT
(a) Engage the 3 claws and install the air duct.
2. INSTALL NO. 1 AIR DUCT
(a) Engage the 3 claws and install the air duct.
3. INSTALL COOLER AIR HOSE
(a) Install the cooler air hose.
4. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY
(a) Install the air conditioning radiator with the 3 screws.
5. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
(a) Engage the claw and install the air conditioning amplifier as shown in the illustration.
(b) Tighten the screw.
6. TEMPORARILY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY
(a) Temporarily tighten the air conditioning unit with the 3 bolts and nut.
NOTICE:
To prevent damage to the installation bracket for the air conditioning unit, be sure to support the air conditioning unit in place.
7. INSTALL INSTRUMENT PANEL REINFORCEMENT
(a) Install the instrument panel reinforcement with the 8 bolts.
8. INSTALL REAR NO. 1 AIR DUCT (for Cold Area Specification Vehicles)
(a) Engage the 2 claws and install the rear No. 1 air duct.
9. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
(a) Install the instrument panel brace with the 2 bolts, nut and screw.
HINT
If the vehicle is equipped with knee airbag, install the knee airbag bracket mounting bolt.
10. INSTALL AIR CONDITIONER UNIT ASSEMBLY
(a) Install the air duct with the 2 bolts.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(b) Install the bolt, nut and 4 screws in the order shown in the illustration.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf) for bolt
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) for nut
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf) for screw 1, 2, 3
11. INSTALL INSTRUMENT PANEL WIRE
(a) Connect the connectors and engage the clamps, then install the instrument panel wire.
(b) Install the ground wire with the bolts.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
(c) Engage the 3 clamps and install the instrument panel wire.
(d) Connect the 3 connectors.
(e) Connect the 3 clamps and install the connector holders.
(f) Tighten the bolt.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
(g) Connect the connectors.
(h) Install the wire harness protector with the screw.
(i) Connect the 2 clamps and install the connector holders.
(j) Tighten the screw.
(k) Connect the connectors.
(l) Connect the 2 clamps.
(m) for Cold Area Specification Vehicles:
(1) Install the ground wire with the bolt.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
12. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY
(a) Connect the back side connectors and install the instrument panel junction block as shown in the illustration.
NOTICE:
Securely connect the connector.
(b) Install the instrument panel junction block with the bolt.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
(c) Connect the front side connectors as shown in the illustration.
NOTICE:
Securely connect the connector.
(d) Engage the clamps.
13. CONNECT DRAIN COOLER HOSE
(a) Install the drain cooler hose as shown in the illustration.
Text in Illustration
NOTICE:
* Install the drain hose with its UP mark facing upward, within the 60 degree range shown in the illustration.
* Install the drain hose without twisting it.
14. INSTALL REAR NO. 3 AIR DUCT (for Cold Area Specification Vehicles)
(a) Install the 2 claws and install the air duct.
15. INSTALL REAR NO. 4 AIR DUCT (for Cold Area Specification Vehicles)
(a) Install the 2 claws and install the air duct.
16. INSTALL REAR NO. 2 AIR DUCT (for Cold Area Specification Vehicles)
(a) Install the 2 claws and install the air duct.
(b) Return the floor carpet.
17. INSTALL DEFROSTER NOZZLE ASSEMBLY
(a) Engage the 2 claws and 3 guides, then install the defroster nozzle.
(b) Engage the clamps and connect the connectors, then connect the wire harness.
18. INSTALL HEATER TO REGISTER DUCT ASSEMBLY
(a) Engage the 3 claws and install the heater to register duct.
19. INSTALL STEERING COLUMN ASSEMBLY
Installation (from 07/2011)
20. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY
Installation (from 07/2011)
21. CONNECT HEATER WATER INLET HOSE A
(a) Connect the heater water inlet hose onto the air conditioning unit.
Text in Illustration
HINT
Perform the installation with the hose clip and mark at the correct angle.
22. CONNECT HEATER WATER OUTLET HOSE A
(a) Connect the heater water outlet hose onto the air conditioning unit.
Text in Illustration
HINT
Perform the installation with the hose clip and mark at the correct angle.
23. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY
(a) Remove the vinyl tape from air conditioner tube, liquid tube and the connecting portion of the unit.
(b) Apply sufficient compressor oil (ND-OIL8) to 2 new O-rings and the connecting part of the air conditioner tube and liquid tube.
Compressor oil:
ND-OIL8 or equivalent
(c) Install the 2 O-rings onto the air conditioner tube and liquid tube.
(d) Securely connect the air conditioner tube and liquid tube to the air conditioning unit.
(e) Turn the hook connector in the direction indicated by the arrow in the illustration.
(f) Insert the pipe joints securely into the fitting holes and tighten the bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
24. INSTALL COWL TOP OUTER PANEL Installation (from 07/2011)
25. INSTALL COWL TOP TO COWL INNER BRACE Installation (from 07/2011)
26. INSTALL FRONT AIR SHUTTER SEAL RH Installation (from 07/2011)
27. INSTALL FRONT NO. 1 VENTILATOR SEAL Installation (from 07/2011)
28. INSTALL WINDSHIELD WIPER MOTOR AND LINK
Installation (from 07/2011)
29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
30. ADD ENGINE COOLANT (for 1NZ-FE)
31. CHARGE REFRIGERANT Service and Repair
32. INSPECT FOR COOLANT LEAK (for 1NZ-FE)
33. WARM UP ENGINE Service and Repair
34. INSPECT FOR REFRIGERANT LEAK Service and Repair